Pumping Unit C-640D-305-168

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Pumping Unit

C-640D-305-168

Operation and Maintenance Manual


Conventional Beam Pumping Unit Operation and Maintenance Manual

CONVENTIONAL BEAM PUMPING UNIT

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Table of Contents

SECTION ONE. SAFETY PRECAUTION Page4


SECTION TWO. GENERAL INFORMATION Page6
SECTION THREE. BRIEF INTRODUCTION OF STRUCTURE Page8
STRUCTURE AND COMPOSITION OF THE UNIT Page8
ASSEMBLY, DISASSEMBLY AND MAIN PARTS Page9
SECTION FOUR. INSTALLATION Page13
FOUNDATION Page13
SETTING AND ALIGNING THE BASE Page14
ASSEMBLY SAMSON POST TO MAIN BASE Page15
ASSEMBLIES LADDER TO SAMSON POST Page15
GEAR REDUCER(WITH CRANKS)INSTALLATION Page16
BRAKE RELEASE AND ADJUSTMENT PROCEDURE Page17
BRAKE LINKAGE ASSEMBLY PROCEDURE Page17
INSTALLATION OF COUNTERWEIGHTS ON CRANKS Page18
INSTALLATION OF PITMAN ARMS TO EQUALIZER Page19
INSTALLATION OF WALKING BEAM TO EQUALIZER Page19
INSTALLATION AND ALIGNMENT OF CENTER BEARING TO WALKING BEAM Page20
INSTALLATION OF WIRELINE ASSEMBLY TO HORSEHEAD Page20
INSTALLATION OF HORSEHEAD TO WALKING BEAM Page21
INSTALLATION OF WALKING BEAM ASSEMBLY TO STRUCTURE Page21
INSTALLATION OF PRIME MOVER Page22
V-BELT INSTALLATION AND ALIGNMENT Page22
SECTION…OPERATION Page23
CHECK BEFORE INITIAL OPERATION Page23
INITIAL OPERATION Page23
AFTER 24 HRS. OPERATION Page24
AFTER FIRST TWO WEEKS OPERATION Page25
AFTER SIX MONTHS AND EACH SIX MONTHS THEREAFTER Page26
SECTION SIX. ADJUSTMENT Page27
COUNTERBALANCE ADJUSTMENT Page27
CHANGING STROKE LENGTHS Page28
SECTION SEVEN. LUBRICATION Page41
SECTION EIGHT. MAINTENANCE Page44
SECTION NINE. QUALITY WARRANTY Page49
SECTION TEN. APPENDIX Page51

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Conventional Beam Pumping Unit Operation and Maintenance Manual

1. SECTION ONE. SAFETY PRECAUTION

Watch out! …
From this symbol throughout the book. It will direct your attention to
information that involves your safety!

Read and understand all assembly and operating instructions and precautions
before attempting to assemble and operate the pumping unit.

PRACTICE SAFETY FIRST

Avoid the possibility of fire when working in the vicinity of an oil well. Be prepared for an
emergency, fire or mechanical failure, in the event that an accident does happen.

The pumping units are constructed of large and heavy rotating parts. When working
around these machines, it is essential that all personnel involved with the installation,
assembly, operation and maintenance of the pumping units use extreme care and good
safety practices at all time. Failure to use extreme care when working with them can
cause severe bodily injury or death.

During assembly of pumping units, a hoisting supervisor should give direction for all
hoisting operations and be located where he is readily visible to hoist /crane operator
and can view all of the hoisting operations. All persons should exercise extreme caution
and stay clear of all objects being hoisted. When working on ladders or work stand,
insure adequate footing and holds to securely assemble the large components.

It should be noted that a pumping unit has components, which can start moving from
the effect of gravity. All personnel should stay clear of the crank and counterweights or
other elements, which may start moving. Times of particular danger from rotating or
moving parts would be during assembly, stroke change, counterbalance change,
general maintenance of any kind. The pumping unit is equipped with a braking system,
but the operator should also devise safety stops from heavy timbers or metal
tubing/channels that can be placed under or against the crank. When the long end of
the crank arm is straight down, no rotation will start when the power source is
disengaged, provided the carrier bar has not yet been attached to the polished rod or

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Conventional Beam Pumping Unit Operation and Maintenance Manual

the well is clamped off.

Be aware of all power line positions prior to beginning installation or


maintenance on or around the pumping unit. Your operation must be
organized to avoid all contact with power lines. Failure to heed this warning
could result in severe bodily injury or death to personnel.

All electrical labor must be performed by a qualified electrician, especially


on pumping units that utilize electric motors, or other related electrical
devices. The electrical components should be regularly inspected and
maintained in a safe operating condition by a qualified electrician.

Attention

Do not operate the pumping unit unless all safety shields and guard rails are
securely fastened in place.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

2. SECTION TWO. GENERAL INFORMATION

INTRODUCTION
The purpose of this manual is to provide instruction on the parameter, structure,
installation, assemble, operation and maintenance of a pumping unit. It will provide the
means for a safe and efficient installation and operation. Due to the size of the pumping
unit and its components, safety must be stressed during assembly, at start up and any
time that maintenance is performed. Before beginning assembly, operation or
maintenance, review the safety precautions section.
The date presented in this manual was current at the time of printing. The photos and
illustrations used in this manual may not look exactly like your pumping unit, but are
representative and specify the correct parts and instructions required to properly
assemble, maintain and operate your particular pumping unit. Improvement and parts
change about the product will not be informed; owner/operator should take the material
object as the standard.

WARNING: some pictures or sketches in this manual show the pumping


unit with safety shields removed for assembly or for a better view of the
subject. The pumping unit should never be operated with any of the safety shields
removed.

These models units (refer to appendix section) are conventional pumping units with
beam balanced. The motive force is furnished in different configurations, depend- ing on
requirements of the customer either the electromotor or natural gas engine.

EXPLANATION OF PUMPING UNIT DESIGNATIONS


Sample: The model C-57D--109—54 pumping unit designations is defined as follows.
C—— Walking beam balanced pumping unit;
57D—— 57,000 inch-pounds peak torque rating;
109—— 10,900 pounds of walking beam capacity;
54—— 54 inches maximum stroke.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

API RATING AND DESIGNATION

The pumping units are designed and rated according to API specifications. This design
and specification calls for the unit to operate at Max.9 strokes (For Type 640D is 8 SPM)
(electromotor configured) or 8 strokes (max) (nature gas engine configured) per minute
and with proper counterbalance adjustment.

PUMPING UNIT DIRECTION

Pumping unit direction: Viewed from the side of pumping unit, the horse-head side is the
front of the pumping unit, the motor side is rear. Facing the front of pumping unit, the
side on the right hand is the right side, on the left is left.

PUMPING UNIT ROTATION DIRECTION

Pumping unit rotation direction: the rotation of this type is the direction of the crank
falling to the rear of the pumping unit; or when standing on the left of the pumping unit
and facing to it, the rotation direction is the crank rotating anti-clockwise.

BOLT TIGHTENING TORQUE VALUES

All bolts used on the pumping unit are important. The surfaces under the bolt head and
nut and the contacting surfaces must be flat, clean, and free of burrs so that the bolted
members join in a "metal to metal" contact. Bolts that are properly tightened according
to the manual will retain their grip under normal operating conditions. Improperly
tightened bolts will break in fatigue and may cause serious failures and injury to
personnel. The following table gives recommended tightening torques.
Table 1. Recommended bolt torque values for grade 5 of USA

Bolt diameter Tightening torques Bolt diameter Tightening torques


3/8"-16UNC 30 to 32 ft lbs. 1"-8UNC 612 to 676 ft lbs.
1/2"-13UNC 71 to 79 ft lbs. 1-1/8"-7UNC 866 to 958 ft lbs.
5/8"-11UNC 143 to 157 ft lbs. 1-1/4"-7UNC 1064 to 1176 ft lbs.
3/4"-10UNC 253 to 279 ft lbs. 1-1/2"-6UNC 1849 to 2049 ft lbs.
7/8"-9UNC 409 to 451 ft lbs.
Note: NC—National Coarse Thread.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

3. SECTION THREE. BRIEF INTRODUCTION OF


STRUCTURE

3.1 STRUCTURE AND COMPOSITION OF THE UNIT


This product structure and main parts refer to figure 1.

Figure 1 Pumping unit structure

1.Wire Line 2.Carrier Bar 3. Polished Rod Slip

4. Horse-head 5. Walking Beam 6. Samson Post

7. Center Bearing Assembly 8. Tail Bearing Assembly 9. Cross Beam

10. Pitman 11. Crank Pin Assembly 12. Crank

13. Gear Reducer 14. Brake Assembly 15. Motor Base

16. Main Base 17. Pressing Bar Assembly

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Conventional Beam Pumping Unit Operation and Maintenance Manual

3.2 ASSEMBLY, DISASSEMBLY AND MAIN PARTS


1) Wire Line
The wire line is composed of multiplayer, nontorsional steel wire. Its length and type
refer to appendix section. There are rope sockets at its two ends whose top joins with
the rope supporter in the horse top and bottom joins with carrier bar.

The wire line is designed according to the API SPEC 11E.

WARING! Check wire line periodically. There should be no


breakpoint and looseness.

2) Carrier Bar
Carrier bar is used to connect polished rod and wire line, high strength and stability.

3) Polished Rod Slip


Polished rod slip is used to connect polished rod with carrier bar tightly. with two sizes,
1″and 1 1/8″.

4) Horse-head
Horse-head is welded with steel plate. Wire line is hung in the horse-head rope support.
The horse-head connect to front of the walking beam.

5) Walking Beam
Walking beam is welded with steel plate shaped H-section. It is designed according to
the requirement of API APEC 11E and has sufficient strength. The front of walking
beam is connected to horsehead by four horsehead pins or a shaft. There has been
installed cross beam bearing frame at the rear end. Whole walking beam is fixed on
support bearing seat.

6) Samson post
Samson post is welded by section steel. It is fixed on the base by bolts and has
sufficient stability.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

7) Center Bearing Assembly


Center bearing assembly, with two anti-frication bearings, is used to connect walking
beam with Samson post. Before installing, sufficient lubricating grease should be added.

8) Tail Bearing Assembly


Tail bearing assembly, with one anti-frication bearing, is used to connect walking bean
with cross beam. Before installing, sufficient lubricating grease should be added.

9) Cross beam
Cross beam is made of steel plate by welding. It is according to the requirement of API
APEC 11E and has sufficient strength.

10) Pitman
Pitman is made up of upper connecting rod head, lower connecting rod head and
seamless steel pipe by welding. Upper connecting rod head has shaft sleeve, which has
abrasion resistance to prevent rustiness with connecting rod. Upper head connect cross
beam by connecting rod pin. Lower head is connected with wrist pin and easy to install
and remove.

11) Crank Pin Assembly


The crank pin assembly, with one anti-friction bearing, has high strength; stability, and
note specially, install and remove crank pin is forbidden.

Caution: Before installing, sufficient lubricating grease should be added.

12) Crank
Crank is made of cast iron. Crank is installed at the two sides of the reducer used
wedge to wedge tightly. Every crank has two differential bolts to lock crank at the
reducer output shaft. There are three wrist pin holes in crank. The wrist pin can be
installed in different hole to get corresponding strokes. There are gear rack and crank
balancing weight in crank. Adjust crank counter weight position through gear rocker arm
to get the best balance efficiency.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

13) Gear Reducer


Gear reducer is divided-flow type,double reduction,involutes herring-bone gearing
reducer; the particular parameters please refer to appendix section. Reducer uses
extremely pressure industry gear oil to lubricate. Gear is based on oil sump immersion
method to lubricate. Bearing of the driving shaft is based on gear oil splash to lubricate.
Bearings of the middle and the input shaft are lubricated by oil wiper.

Oil level indicator has been installed in reducer box to check oil level. Dipstick slot has
been installed on reducer cover to check oil level by dipstick.

Reducer is installed on base barrel. Draft shaft two ends have installed crank. Input
shaft left-end is mounted with brake wheel and right-end is mounted with big adhesive
tape wheel to transfer dynamic force.

Caution: Reducer middle shaft and draft shaft covers have oil slot. When maintaining
them, pay attention to its position and there should be no oil way plug, otherwise,
bearing will lack lubricate oil to cause destruction of middle shaft bearings and output
shaft bearings.

WARING! Check brake wheel and reducer drive sheave periodically. There
should be no flabby instance occurred.

14) Brake Assembly


The brake assembly is cable type brake system. One end of the assembly connect with brake
lever, the other is fit on brake drum. Because of considerable unit inertia, braking do
should be smooth, instead of sudden!

15) Mover Assembly


The pumping units are driven by prime movers, which are electric motors or nature gas
engines as per the requirements of customers. Mover is installed on the guide rail,
which is based on guide rail beam. Mover guide rail is made of shaped steel by welding
or casting iron. The jackscrews can adjust motor and tighten drive adhesive tape.
Manufacturer configured three small pulleys with different diameters, user can change
different pulley to get corresponding stroke frequency.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

16) Base
Base is used to support and fix pumping unit, with sufficient stability.

Note: Base must be sit on concrete foundation, which should steadily sit compaction
ground and pumping unit base has no vibration, otherwise, it might fracture.

17) Pressing Bar Assembly


This assembly is used to fix the base on the concrete foundation tightly.

Caution: Check bolts periodically to prevent pumping unit from vibrating and shaking.

Warning: The soil under concrete foundation must be compacted. Concrete


foundation must fill with solid and align. When operating pumping unit, concrete
foundation should not vibrate and pumping unit should not vibrate. If concrete
foundation is not steady, pumping unit base may fracture or bring some other failures.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

4. SECTION FOUR. INSTALLATION


Pumping unit installing orientation

Consider the local main wind direction to avoid the leaking gas and oil liquid blowing to
the pumping unit and motor. The well field conditions must also be considered in order
to secure enough space for oil service easily.

Notice: Before installation, consider stroke length, carrier bar lower dead point height
and wellhead height enough to make appropriate height concrete foundation. We
suggest that concrete foundation height isn’t less than 350mm (13.78in).

4.1 FOUNDATION

The foundation is prefabricating 200# concrete made from 400# ordinary concrete.
Customer can prefabricate integral or segment foundation to move easily. The
recommended install plans and foundation style please refer to appendix.

The foundation should be positioned in accordance with a foundation plan only. A copy
of this plan may be shipped with the unit. This foundation plan shows the hold down bolt
location in relation to the wellhead, bolt and anchor nut sizes and number. No attempt is
made on the foundation plan to prescribe the shape, depth nor characteristics of the
foundation. The contractor must supply this information based on their knowledge of
and experience with the soil conditions as they exist at the well site and assume full
responsibility for the quality of the foundation.

Foundation tie down bolts must be hammered tightly after concrete has been set up and
pumping unit base alignment is completed.

The bottom of concrete foundation must be filled with gravel. Unsteady foundation may
cause the broken of the unit's base easily.

Levelness of the concrete foundation upper surface should be checked from the front to
rear, right to left and draw out the foundation's central line. The central line shall point
straightly to the wellhead center. Their lateral differential is not over 10mm (0.4in).

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Whether integral or segment concrete, pumping unit anchor bolts must be credible, tight
and take anticorrosive steps. Measure is filled with soil into anchor bolt bore, then seal
with asphaltum.

4.2 SETTING AND ALIGNING THE BASE

Review the safety precaution of this manual prior to beginning erection of the pumping
unit.

Step 1: Mount base on concrete. Central line mark


hole on base should be adjusted carefully to make
the line center direct the well head. There differential
is not over 1mm (0.04in) per meter and assemble
differential isn’t over 3mm (0.12in).

Step 2: Adjust base position. The dimension


differential from vertical projection of supporter
bottom plate on the support top plate center(mark
hole on the supporter body) to well head is±
2.54mm(±0.1in).

Step 3: Adjust base levelness. Vertical levelness differential is not over 2.5mm per
meter(≤0.03in/ft)and front is high, back is low. horizontal levelness differential in cross
direction is not over 2.0mm per meter (≤0.024in/ft). upper flat horizontal levelness
differential is not over 1.5mm per meter (≤0.018in/ft)

Step 4: Adding sloping iron or backing plates under the


base can adjust the base and concrete foundation
horizontal. The number of backing plates in each group
shall not exceed 3 pieces; its total thickness is less than

10mm and the contact shall be secured


homogeneous.
After adjustment, fix substructure body on
concrete foundation by anchor screws.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

4.3 ASSEMBLY SAMSON POST TO MAIN BASE

Step 1: Assemble the rear leg to the front Samson post, using the bolts furnished. Do
not tighten the bolts securely at this time.

Step 2: Thread the lifting chain, or cable, between


the support beams and around the top bracket. Lift
and position the Samson post on the base.

Step 3: Use a plumb to align the holes of the


Samson post with the base.

Step 4: Insert and tighten all bolts that secure the


Samson post assembly to the unit base.

Step 5: Tighten all bolts at the top of the rear


support beam using an alternating sequence from
one side of the unit to the other. This will avoid
inducing uneven stresses in the flanges.

4.4 ASSEMBLIES LADDER TO SAMSON POST


Notes: ladder is commonly configured on higher rated torque models of units, not
configured on lower rated torque models.

Step 1: Assemble four braces and two support beams to the ladder, leaving the bolts
only hand tightened. Of two support beams, the longer is used at the top of the ladder,
the shorter at the bottom of the ladder.

CAUTION: All bolts should be installed so that the bolt heads are on the inside of the

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Conventional Beam Pumping Unit Operation and Maintenance Manual

ladder.

Step 2: Position the ladder safety ring on the outside of the


ladder rails at the top of the ladder and screw down
securely.

Step 3: Lift the section of ladder, lean against the Samson


post.

Step 4: Position the ladder against the Samson post and


tighten all bolts securely.

4.5 GEAR REDUCER(WITH CRANKS)INSTALLATION


WARING! The reducer with cranks is an assembly that comprises heavy
rotating components. All personnel must exercise extreme caution when lifting
this assembly to ensure that the cranks are locked to prevent rotation.

Step 1: Install two cranks to each output shaft ends


of reducer, take steps to ensure key match the shaft
securely and tightly.

Step 2: To install the reducer on main base, attach slings or chains to the reducer and
both cranks for proper stabilization. Mark the centerline on top of the base and bottom
of reducer for initial alignment. Place the reducer on drum of base, insert bolts and a
hydraulic screw down.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Step 3: Set the cranks down to a safe position. Remove the chains from reducer but
not cranks. Disengage the brake lock-out and clear the crank sweep area. Slowly
release the brake lever to allow the cranks to rotate to bottom dead center. The chains
may now be removed from the cranks

Step 4: Measure the distance from each end of the crankshaft to the alignment mark. If
they are not equal, adjust it, then Tighten all bolting on gear reducer and bolting on
sub-base.

Step 5: Tighten all gear reducer bolts.

4.6 BRAKE RELEASE AND ADJUSTMENT PROCEDURE

Step 1: Release the brake by loosening the brake


(See the arrow).

Step 2: To adjust the brake pads, continue


loosening the adjust nut till the proper clearance is
gotten between the brake lining and the hub.

Step 3: Tighten the nuts and adjusters bolts for proper adjustment.

4.7 BRAKE LINKAGE ASSEMBLY PROCEDURE

Step 1: Connect one end of the vertical rod to the bell crank and secure it with the
adjusting rod nut.
Step 2: Loosen the lock nuts and adjust the vertical
brake rod length so that the bell crank is horizontal
when the brake pads contact the hub.

Step 3: Connect the upper end of the vertical rod to


the cam.

Step 4: Connect one end of the horizontal


brake rod to the yoke at the brake handle
assembly.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Step 5: Adjust the length of the horizontal rod between the bell crank and the brake
handle so that the cam is approximately horizontal when the brake handle is in the
forward position.

Step 6: Connect the other end of the horizontal rod


to the bell crank.

Step 7: Tighten all yoke nuts and bolts, apply


pull-force to the lever to test the brake effect for the
whole brake system, it isn’t over 150N.

4.8 INSTALLATION OF COUNTERWEIGHTS ON CRANKS

Step 1: Set the brake.

Step 2: Insert a chain or cable through the holes in


the counterweight.

Step 3: Install the "T" bolts in the slot of the crank.

Step 4: Set the counterweight on the bolts.


Step 5: Install a flat washer, a standard nut, and jam
nut on each of the counterweight bolts and tighten
securely.

Step 6: Repeat the installation procedure; ensure each of the counterweights to be


installed.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

4.9 INSTALLATION OF PITMAN ARMS TO EQUALIZER

Step 1: Position the equalizer on the ground so that the equalizer bearing housing bolt
holes are on top of the beam.

Step 2: Select the pitman arm which has the lubrication line attached to it(if configured).
Note the position of the lubrication line on the equalizer. Two sets of lubrication lines are
assembled on the same side.

Step 3: Equalizer holes should be cleaned thoroughly before inserting upper pitman
pins in housings. Pitman pins should be covered with anti-rust grease.

Step 4: Mount the pitman to the equalizer beam


and insert the upper pitman pin in the housing holes.
Install the bolts and tighten them.

Step 5: Connect the lubrication line from the pitman arm to the equalizer (if configured).

Step 6: Attach and assemble the other pitman member according to the same
procedure.
4.10 INSTALLATION OF WALKING BEAM TO EQUALIZER

Step 1: Loosen the bolts on the two-equalizer


flanges and install on the equalizer bearing
assembly pin (already attached to walking beam).

Step 2: Position the flanges on the equalizer


assembly to align with those on the equalizer beam.

Step 3: Install bolting, nuts and tighten


with hammer wrenches.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

4.11 INSTALLATION AND ALIGNMENT OF CENTER BEARING TO


WALKING BEAM

Step 1: Position center bearing on the ground with


larger mounting flange facing upwards.

Step 2: Lift the walking beam and position the center of the beam on the center bearing.
Insert the bolts and loosely tighten.

Step 3: To align the center bearing, measure the


distance from the front of the walking beam to the
center of the center-bearing shaft. When
measurements on both sides are equal, tighten the
bolts securely.

4.12 INSTALLATION OF WIRELINE


ASSEMBLY TO HORSEHEAD

Step 1: Place the wire line assembly in position on


the horse head.

Step 2: Install the bolts in horse head to secure the wire line Assembly.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Step 3: Position the carrier bar so that it is relatively straight with the open end facing
the polish rod.

Step 4: Install the horse head adjusting bolts.

4.13 INSTALLATION OF HORSEHEAD TO WALKING BEAM

Step 1: Lift the horse head into position and place


the roll bar behind the flange on the walking beam.

Step 2: Install the safety flag through the horse head


and angle slot on the walking beam and tighten adjusting bolts
4.14 INSTALLATION OF WALKING BEAM ASSEMBLY TO
STRUCTURE

Step 1: Attach lifting ropes near each end of the


walking beam assembly to ensure a level lift.

Step 2: Position the center bearing housing on the top of the Samson post. Insert the
bolts and hand tighten

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Step 3: Attach the pitman arms to the crank pin


assemblies and securely tighten all bolts.

Step 4: Attach one of flexible hoses on the Samson post to the center bearing, the
other flexible hose to the walking beam.

4.15 INSTALLATION OF PRIME MOVER

Position the slide rails on the slots near the end,


which is toward the reducer so that the belts can
more easily be installed after positioning the prime
mover. Face the slide rail to match the mounting
holes on the prime mover. Similarly install and
space the bolts in the slots on the slide rails.
Carefully lower the prime mover onto the slide rails.
Install the nuts without tightening until the belt alignment is complete.

4.16 V-BELT INSTALLATION AND ALIGNMENT

Install a matched set of belts, always using the


inside grooves if either sheave has an excess
number of grooves. Utilize a string to align the
inside faces of the sheaves (see right picture).
Shift the prime mover as required and then tighten
the bolts that attach the prime mover to the slide
rails. Tighten the belts by using the adjustment screws. All new belting should be
rechecked for tightness after 24 hours.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

5. SECTION…OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

5.1 CHECK BEFORE INITIAL OPERATION

a) After erection of the unit is complete, the following checks must be carried out:
b) Check if the foundation is steady and solid.
c) Check and fasten all anchor bolts.
d) Check all the lubricating points to ensure all of them have been lubricated very well.
e) Check all the connection parts to ensure all of them have been connected well.
f) Check driving belt, the tension should be proper.
g) Check brake, it should be flexible and reliable.
h) Check if the installation of electrical circuits and appliances abide by technical and
safety requirements.
i) Check the unit if there are external substances hindering the running of the unit, if
does, clean all.
j) Check the belt-guard (if confined) and ladder to ensure all of them are fixed firmly.
k) Pay special attention to that if the lock dog of the unit's brake safety system has
been lifted and the brake has been loosening.

5.2 INITIAL OPERATION

a) Start the pumping unit; five minutes later brake the unit and check if the wires is
tortuous in running, adjust it.
b) Carrier bar should be horizontal and have no incline and no bending, otherwise,
adjust it.
c) Tension of driving belt should be proper, not too tense or any sliding, otherwise,
adjust it.
d) Horse-head should not have any vibration in running.
e) Samson Post shouldn't have any oscillation in operation.
f) The reducer shouldn't have any oscillation in operation.
g) The prime mover shouldn't have any abnormal sound in operation.
h) Brake should be flexible and reliable.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

i) Check all the connection bolts ensure all of them are fixed firmly.
j) After you have done all the above, please dislodge the safety measures and restart
the prime mover.

5.3 AFTER 24 HRS. OPERATION

Listen for unusual noises. If any occur, locate cause and take necessary corrective
action.

Apply brake slowly several times to be sure it is functioning properly before using it
position cranks.

DO NOT JAM BRAKE. Always apply brake slowly and firmly.


Caution: Abrupt braking may shear gear teeth in reducer causing excessive
down time.

Stop prime mover and slowly apply brake to stop pumping unit with cranks
horizontal toward well.

When brake holds cranks without slippage, release brake solely and allow cranks to
re-position themselves in the DOWN position .If prime mover is electric, be sure
master switch is locked out. Chain or block cranks to prevent their movement.
Clamp of well at stuffing box.

Danger! Do not work on or near cranks or counterweights until they are chained or
blocked to prevent their movement. Serious injury or death could occur if you do so.

Check all bolts including hold down clamp bolts for tightness.

Re-tighten prime mover hold down bolts.

Re-check alignment to make sure that wire line tracks horse head properly.

Remove chains or blocking from cranks, remove wellhead clamp at stuffing box, release
break and start prime mover to resume pumping.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

5.4 AFTER FIRST TWO WEEKS OPERATION

Listen for unusual noises. If any occur, locate cause and take necessary corrective
action.

Apply brake slowly several times to be sure it is functioning properly before using it
position cranks.

DO NOT JAM BRAKE. Always apply brake slowly and firmly.


Caution: Abrupt braking may shear gear teeth in reducer causing excessive
down time.

Stop prime mover and slowly apply brake to stop pumping unit with cranks horizontal
toward well.

When brake holds cranks without slippage, release brake solely and allow cranks to
re-position themselves in the DOWN position .If prime mover is electric, be sure master
switch is locked out. Chain or block cranks to prevent their movement. Clamp of well at
stuffing box.

WARNING! Do not work on or near cranks or counterweights until they are


chained or blocked to prevent their movement. Serious injury or death could
occur if you do so.

Check reducer oil level. If the level is low, remove the inspection cover and add oil to the
proper level.

Visually inspect the structural bearings for oil seal leaks. This would include the crank
pin, equalizer and center bearing assemblies. Grease fittings are located at ground level,
and if needed, the grease should be pumped in slowly to avoid pushing out the oil seals.

Check all bolts including hold down clamp bolts for tightness.

Re-tighten prime mover hold down bolts.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Remove chains or blocking from cranks, remove wellhead clamp at stuffing box, release
break and start prime mover to resume pumping.

5.5 AFTER SIX MONTHS AND EACH SIX MONTHS THEREAFTER

Before do the maintenance for the pumping unit, you must obey all the safety
specifications mentioned above.

It is recommended that an oil sample be taken every six months to determine condition
of the oil. Collect a typical sample of the reducer oil in a transparent receptacle. A visual
inspection will expose possible dirt, sludge, water emulsion, or other forms of
contamination. You may also desire to determine that you have any of the following
conditions in the lubricant, check with a qualified vendor regarding replacement:

a) An acid or singed odor indicates oxidation of the oil to the degree that it should
be replaced.
b) If sludge is observed in the used sample, the oil should be replaced or filtered to
remove the sludge. This condition is prevalent if the lubricant has not been
changed for a long period of time.
c) If water exists in the used sample, the water should be completely drained from
the reducer. Subsequent bubbling will occur with as little as 0.1% of water
present in the oil. If there is greater than 0.2% water by volume, an oil change is
recommended.

Visually inspect the wire line for wire fraying. A rusty wire line should be cleaned and
coated with a wire line lubricant as specified in the manual.

Belts’ alignment and tension should be checked and adjusted to prolong their life. Under
normal utilization belts will stretch and wear. It is recommended that new belts be
retightened after the first 24 hours of operation.
Check all bolts. Retighten all bolts according to the table 1.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

6. SECTION SIX. ADJUSTMENT

6.1 COUNTERBALANCE ADJUSTMENT

Efficient operation, torque loading, and maximum life of a pumping unit are all
dependent on the proper counterbalance. Counterbalance requirements can be
determined very accurately or estimated by various methods.

1) Polished rod dynamometer:

A dynamometer card analysis is the most accurate method for determining loading and
counterbalance. This involves using a dynamometer to record the well load through a
stroke cycle and then using torque factors to determine the reducer torque and
counterbalance required for balanced conditions.

2) Ammeter:

A clip on ammeter may be used to compare the up-stroke and down-stroke current on
electrically powered units. When the counterbalance is adjusted so that the current
peaks are equal, the unit will be roughly in balance.

3) Vacuum Gauge:

A vacuum gauge may be used to compare torque peaks on engine driven units much
similar the ammeter is used on electrically driven units. Vacuum pressure decreases as
engine output increases.

4) Sound of the Prime Mover:

An approximate estimation of balance can be made by listening to the characteristic


sound of the prime mover as it drives the unit. Some speed changes will occur as the
peak loads are approached; speed changes will cause the sound of the prime mover to
vary.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

5) Belt Tension:

Belt tension and subsequent belt stretch increases with load. This causes a proportional
amount of slack in the belts on the side opposite the direction of rotation of the prime
mover. A visual inspection of the belt sag on up stokes or down stoke, can be used to
estimate counterbalance.

6)Counterweight Adjustment

Rotate the unit and apply the brake so that the crank is slightly downhill in the direction
that the weights are to be moved. Set the brake, engage the brake lockout bolt or pawl,
and secure the cranks against rotation. Loosen the counterweight bolts just enough to
allow the weights to be moved. Use the pinion adjusting wrench to move the weights to
the desired position. It is important to note that larger weights may have to be moved
with the aid of a crane or a pry bar. The weight on the crank may be moved in a similar
manner. After positioning the weights in the desired location, tighten the counterweight
bolts utilizing recommended levels of tightness, and add a second nut for a jam nut.

6.2 CHANGING STROKE LENGTHS

Locate the cranks at approximately the 2 o'clock position and set the brake. Place a
polished-rod clamp at the stuffing box and tighten according to the clamp
manufacturer's recommendations. Using the prime mover or a crane-lift, relocate the
cranks to the 12 o'clock position and set the brake.

You may now disconnect the carrier bar from the polished rod. Insert a long chain
through the carrier bar and install the gate back into the carrier bar. Hold the end of the
chain and pull the carrier bar away from the polished rod while slowly releasing the
brake and letting the cranks down to the 4 o'clock position.

Always disconnect or lockout the prime mover. Remove the crank guard side panel to
gain access to crank area, secure the unit against rotation by the brake lock out bolt or
pawl. Place one 1-1/2 ton come-a-long between the carrier bar and the front
cross-member of the base. Place another between the equalizer and the holes on the
front of the sub-base. Tighten both come-a-longs to restrain possible movement or tilting

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Conventional Beam Pumping Unit Operation and Maintenance Manual

of the walking beam that will occur once the crank pins are removed from the cranks.

1)Crank Pin Removal

Remove the cotter pin and then remove the crank pin nut using the box end hammer
wrench (furnished as an option), and a minimum 14 pound sledge hammer with a full
length handle. Drive out the crank pin using a drive nut and tools above. The drive nut
(furnished as an option) is screwed on until it bottoms on the end of the pin. Hammer
against the head of the drive nut until the pin is loose. If a drive nut is not available, it is
recommended that the hammer hit as squarely on the end of the pin as possible to
prevent surface damage. Once the pin becomes loose, do not remove it from the hole.
Remove the drive nut and install the original nut three or four threads deep. This
procedure should also be used on the opposite crank pin.
Check the crank pin clearance in the hole and adjust come-a-longs accordingly so that
when the pins are removed they will not fall nor pull up in a sudden motion. Remove the
nuts and pull the crank pins out of the crank holes. The pitman side members will
support the crank pin bearing assemblies until the pin is installed into another hole. It is
recommended that rust preventive be applied to the crank pin bore after the pin is
removed.

2)Crank Pin Installation

Step 1: Use a safe solvent to clean the crank pin,


crank pin hole, and the surface of the crank that the
nut will seat against. Remove all paint, burrs, and
other foreign matter from these areas. Always inspect
the crank pin and hole surfaces for rust or wear, as these conditions may indicate that
the crank pin was loose. Use a spot bluing to check the contact between the pins and
the new holes.

Step 2: Adjust come-a-longs to line up the crank pins


with the proper holes for the stoke length desired.
Apply a filmy coat of oil on the tapered pin, threads,
and crank pin hole. All excess oil should be wiped off
with a clean cloth prior to inserting the crank pin high

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Conventional Beam Pumping Unit Operation and Maintenance Manual

alloy bushing into the crank hole.

Step 3: Install the crank pin bearing assembly.

Step 4: Using the box end hammer wrench (see the


arrow), tighten the crank pin nut as tight as possible
by hand. This will establish the metal to metal
position for the final tightening procedure.

Step 5: Using a sledge hammer on the wrench, turn the nut two cotter pin notches past
the hole in the pin and line up the hole in the pin with the third cotter pin notch. Install
the cotter pin. Never back the nut off to insert the cotter pin. If you have turned the nut
too far, remove the crank pin and repeat all of the installation procedures.

3) Returning the Unit to Operation

With the brake engaged, remove the come-a-longs, unchain the drum and disengage
the lock out bolt or pawl.

Reinstall the crank guard panels.

Hold the carrier bar away from the polished rod with the chain and slowly release the
brake to let the cranks go to the bottom. Engage the prime mover (or crane) to slowly
reposition the cranks at 12 o'clock while holding the carrier bar away from the polished
rod. Remove the chain from the carrier bar and attach the carrier bar to the polished rod,
please note that the bottom hole pump spacing will need to be checked and the
polished rod clamp may have to be repositioned to accommodate the new stroke length.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Slowly release the brake to transfer the well load back to the carrier bar. Make certain
that the load isn’t on the polished rod clamp at the stuffing box. If necessary, use the
prime mover to lift the load. Remove the polished rod clamp at the stuffing box that was
used to clamp off the well load.

It is important to note that after a stroke length change, the counterbalance should be
checked and repositioned for the proper balance.

ADJUSTMENT CALCULATION

Pumping unit equilibrium directly influences reducer and motor load, life and whole
machine running stability. So before erecting the pumping unit, preliminary equilibrium
should be calculated and adjusted according to the situation of the oil well and the
pumping unit, in order to avoid the serious non-balance when the pumping unit working.
After pumping unit put into production, adjust equilibrium according to crankshaft actual
torque to assure pumping unit operate in the best condition.

1. Preliminary calculation of the pumping unit

Before erecting the pumping unit, preliminary equilibrium should be calculated and
adjusted according to the situation of the oil well and the pumping unit, in order to avoid
the serious non-balance when the pumping unit working.

balance torque required when calculating MBlance


Calculating according to one of the following formula:
MB l a n c e
 rod - G + POil
=0.470 x( PSocker  /2)× S ①

TF75  Pmax  Pmin 


M Blance  ②
2 sin 75

| MUp max |  | M Down min |


M Blance  ③
2 sin 75

Note:
MBlance, balance torque (N.m);
Pr o ,d weight of the sucker rod inside oil (N);

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Conventional Beam Pumping Unit Operation and Maintenance Manual

 , weight of the oil column on the sectional area of the oil pump plunger
POil
above the dynamic liquid level (N);
G , weight of the construction non-balance (N);
S , length of stroke of the pumping unit (m);
TF 75°, factor of the torque when crank angle of the pumping unit is 75°(m);
Pmax, the maximum load of the landing top (N);
Pmin, the minimum load of the landing top (N);
MUp max , the maximum moment of torsion between the load of the up-stroke
landing top and the crank axis (Nm);
MDown min , the minimum monument of torsion between the load of the down-
stroke landing top and the crank axis (Nm);

Besides:
 =q' L= PS(1-r/7.85)=qL(1-r/7.85)
Prod ④

P'Oil = r³L'³F³g³1000 ⑤

MUp max =(Pmax-G)³ TF 75° ⑥

MDown min =(Pmin-G)³ TF 285° ⑦


Note:
PSocker rod, weight of the sucker rod in air (N);
q' , weight of the sucker rod per meter in the oil (N/m);
L , depth of the pump setting (m);
L', depth of the dynamic liquid-level (m);
r , density of oil-liquid (kg/m3);
F , sectional area of the pump plunger (m2);
g , acceleration of gravity (N);
TF 285° , factor of the torque when crank angle of the pumping unit is 285°
(m);

Pmax and Pmin can be read from relevant documents, or calculated according to the
experience formula or the following formula.
 + Prod ³(1+ S ³ N 2 /1790 )
Pmax = POil ⑧

Pmin = Prod ³(1- S ³ N 2 /1790) ⑨

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Or,

 + Prod
Pmax =( POil  )³(1+aUp/g) ⑩

 ³(1+7.85/(7.85-r) ³aUp/g)
Pmin = Prod ⑾

Note:
N , stroke frequency of the pumping unit (L/min);
aUp , the maximum acceleration of the landing top up-stroke.

Calculating the mounting place of the counterweight

a. According to the following formula Z X


Z X =( M Blance - MCrank )/ QWeight ⑿
Note: Z X , distance between the gravity center of crank counterweight and the
crank axis bore (refer to figure 2) (m).
MCrank , counterbalance moment between the double crank body (Nm);
QWeight , total weight of the counterweights (N);
and
QW e i g h=
t WWeight ³ n p ⒀

Note:
WWeight , weight of single counterweights (N)(refer to appendix);
n p , the amount of the counterweight in general, 4 or 2 pieces.
b. According to counter weight position and distance mark on crank

Gravity center of counter weight is situated at the cross of the two vertical connecting
lines between three hoisting bores and one safety locking segment bore. When install,
gravity center is pointed by safety locking segment bore. Gravity center of counter
weight refer to figure 2 .

Counter weight assembly barycenter position: one counter weight position is its gravity
center; two counter weights position is the connecting line center of the two counter
weights gravity center (or connecting line center of the two counter weight safety

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Conventional Beam Pumping Unit Operation and Maintenance Manual

locking segment bore). Refer to figure 2.

At the crank rack bar, cast scale marks has ―0.5、1.0、1.5‖ to show that the distance
between scale marks and crank shaft bore is 0.5m(19.69in) , 1m(39.37in), 1.5m
(59.06in).

Note: some factory use ―△‖ to point scale marks to show counter weight position.
Counter weight position is according to factory explanation.

Figure 2 Gravity center of the counterweight

2. Examination of the pumping unit equilibrium

After beginning to work, the pumping unit must be confirmed non-overload and
well-balanced. Examination of the pumping unit balance, power balanced method,
torque moment balanced method or current balanced method can be all used.

For example, the current balanced method means when unit has its balance been
adjusted, the maximum different current value between the up-stroke motor and the
down-stroke motor of the pumping unit should be confirmed to be no more than 15% of
the maximum current. That is : current balanced rate,  ≥85%:
| IUp max-I Downmax |
  (1  )  100%  85% ⒁
I max

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Note:
 , current balanced rate of the motor;
IUp max , the maximum current of the up-stroke motor (A);
I Down max , the maximum current of the down-stroke motor (A);
I max , the maximum current of the motor when the pumping unit rotate on
circle (A).

3. Calculating on exactly adjusting balance after the pumping unit begins to


work

After the pumping unit begins to work, the balance should be exactly adjusted within 48
hours. When the work factor of the pumping unit adjusted, the balance should be
exactly adjusted at once.

According to the pumping unit working condition, oil well pump and pumping rod, the
balance should be adjusted in order that the pumping unit should work under the best
balance condition. Now we can adjust and calculate according to the following two
methods:

a. The Current Method

M I I
m ZX   Up m a x Do w mn a x

QWeight IUp m a x+ I Do w mn a x

Note:
mZX , distance that the assembly gravity center of the crank counterweight
should move in order to reach to the balance (m);
mZX >0 meaning that the assembly gravity center should depart from the
crank axis center to moving outside;
mZX <0 meaning that the assembly gravity center should move to the crank
axis center.

M  calculating according to the following methods:


M  = Mn max =30 S +0.236 S ( Pmax - Pmin ) ⒃

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Conventional Beam Pumping Unit Operation and Maintenance Manual

M  = Mn max =0.236 S ( Pmax - Pmin )-100 N 2 ⒄


M  = M X = MCrank + QWeight Z X + G ³ TF 75° ⒅

Note:
Mn max , the maximum net torque of the crank axis;
M X , effective counterbalance torque (N.m).

Pmax and Pmin have the same meaning as the above, but Pmax and Pmin should be
obtained from the indicator diagram in the near future.

According to calculated m ZX to adjust balance.

Note: The current method has its limits. When pumping unit is imbalance seriously,
that is, one of the IUp max or the IDown max is motor generated feedback current, this
formula can’t be used.

When IUp max<0, move the counter weight to the crank shaft center closely; When
IDown max <0, move the counter weight to the crank shaft center far away;
When IUp max>0 and IDown max >0, according to current method to calculate
accurately.

Two recommended ways can be used to judge motor’s feedback current in up-ward or
down-stroke approximately.

The 1st way: if panel box has installed watt-hour meter, see if the watt-hour meter
aluminous pan reverse in up-ward stroke or down-stroke max current. If reverse, there
is feedback current.

The 2nd way: when the pumping unit max current in upward stroke or down stroke,
listen to motor sound and see motor rotate speed, if the rotate speed has exceeded
rated value, there is feedback current.

b. The Torque Method

Step 1: calculating on the net torque of the reducer (Mn)

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Mw = TF ³( W - G ) ⒆
Tn= TF ³( W - G )- M ³ sin (   ) ⒇

Note:
Mw, torque of the polished rod (N.m);
Tn, net torque of the reducer (N.m);
TF , factor of the torque, the crank angle  ;
W , the load of the landing top, the crank angle  ;
M ,the maximum torque of the rotation counter weight N.m;
 , crank angle of rotation (°);
τ, phase out crank angle;

M = MCrank + QWeight Z X (21)


The value of W can be obtained from the indicator diagram in the near future according
to the calculating case of China Standard SY5044-2003, operation and maintenance
of the beam pumping unit A.3 the factor of the polish rod palace required, please refer
to appendix.

, the observer should stand in the left of the pumping unit and face to the pumping
unit, and the well head is in the right of the observer, it is the crank angle per clockwise
direction rotation and started from the 12:00 clock place.

Tn, calculating result see table 2 (that is: calculating sheet of the net torque of the
reducer).

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Table 2 Gear Reducer Net Torque Calculating Table


(Conventional crank balanced unit)
Well no. Company
Unit size Location
Crank
rotary angle sinθ W G W-G TF TF (W-G) -M(sinθ) Tn
θ(°)
0 0
15 0.259
30 0.500
45 0.707
50 0.866
75 0.966
90 1.000
105 0.966
120 0.866
135 0.707
150 0.500
165 0.259
180 0
195 -0.259
210 -0.500
225 -0.707
240 -0.866
255 -0.966
270 -1.000
285 -0.966
300 -0.866
315 -0.707
330 -0.500
345 -0.259
360 0

Note:
Tn  TF (W  G)  M sin 
Where:
Tn =Net reducer torque. In .lbs TF =Torque factor at  .in.
 =Position of crank. CG at 270 degrees=___________________
M=maximum moment of counterbalance. In .lbs
M=(CG at 270 degrees-G ( TF at 270 degrees))=_____________________
W=measured polished rod load at  . lbs.
G=unit structural unbalance. lbs.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

ZX , same to the before-mentioned, that is to say, position of the original balancing


weight installation aggregative barycenter.

Step 2: draw the curve graph of the net torque after calculated according to the formula
15 and table 2, the Mn -  and Mw -  curve graph of the net torque should be
drawn.

Step 3 : calculate reducer net torque equilibrium ratiosηBlance,,ηBlance≥85%.


If the equilibrium ratios cannot reach 85%, pumping unit will be unbalanceable.
Adjust counter weight position.

Step 4: calculating the balance torque M Blance


| MUp max | + | M Down min |
M Blance  ⒄
| sin Up |  | sin  Down |

Note:
M Blance , balance torque (N.m);
Up , crank angle corresponding to MUp max ;
 Down , crank angle corresponding to M Down min ;

MUp max and M Down min same to the before-mentioned, that is to say, they can be
obtained through calculating indicator diagram of work in the near future and
reading max in the up-ward stroke , down-stroke on Mw-θcurve graph of the net
torque.

Step 5: calculating the place of the gravity center of the counter weight ( Z X )
Z X can be calculated according to the formula 12.

According to Z X to adjust pumping unit balance. If the balance rate can’t reach
100%, MUp max may be bigger than M Down min .

4. balance rate of the net torque of the reducer

Calculating the net torque of the reducer, the balance rate  Blance should be more
than 85%:

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Conventional Beam Pumping Unit Operation and Maintenance Manual

 | M nUp max |  | M n Down min | 


 Blance  1    100% ⒅
 M nUp max 
 

Note:
 Blance ,balance rate, Blance ≥85%;
Mn Up max, the maximum moment of torsion of the up-stroke reducer (N.m);
Mn Down min ,the minimum monument of torsion of the down-stroke reducer
(N.m).

5. Common unit conversion table

1 ft=12 in=3048 mm 1 lbf=4.44822 N

9
1 in=0.0254 m=25.4 mm 1 ℃= °F+32
5

1 L=1 dm3 1 horse power=735.499 W

1 US gal=3.78543 dm3 1 rad=57.2958°

1 bbl=0.15898806 m3 1 kgf²m=9.80665 N²m

1 lb=0.453592 kg 1 lbf²ft=1.35582 N²m

1 kgf=9.80665 N 1 lbf²ft=0.112985 N²m

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Conventional Beam Pumping Unit Operation and Maintenance Manual

7. SECTION SEVEN. LUBRICATION

All structural bearing assemblies and the gear reducer are designed to provide years of
trouble-free service, if proper maintenance are observed by the user at recommended
intervals. Many factors govern the lubrication requirements and maintenance practices,
with some factors peculiar only to certain areas due to type of terrain, prevailing weather
conditions and type of production. The information contained herein may not completely
satisfy the necessary requirements of all pumping units, but if strictly observed as to
lubrication points and type of lubricants, unit downtime will be minimal. Lubricants and
time intervals specified are formulated on normal use of pumping units. If unit is used in
extreme environmental conditions, with exceptional heavy loads or excessive speeds,
time intervals between servicing may need to be adjusted. Lubricant types
recommended may also require change to assure continued satisfactory operation.
The unit's lubricating sites and requirements refer to figure 3 and table 3.

Figure 3 Pumping unit lubricating sites

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Conventional Beam Pumping Unit Operation and Maintenance Manual

The lubricating of reducer shall pay attention to:

1) No use of the nonstandard lubricating oil.


2) No mixing use of different qualities lubricating oils.
3) In the areas where season temperature is permitted, one brand lubricating oil can be
used in the whole year.
4) If one brand of lubrication oil is not enough, proper brands lubrication oil shall be
chosen and replaced in spring and autumn.
5) Reducer box bottom amass water easily, check it frequently and clear the water to
prevent oil emulsification.
6) Check reducer lubricant periodically to do oil analysis, and then determine exchange
time according to water cut and impurity ratio in oil.
7) In order to extend using life of reducer, lubricating oil should be kept clear and away
from the materials such as mud, sands, and iron filings etc.
8) Periodically take samples to check lubrication oil of reducer; under the following
conditions, new oil shall be changed.
a. There is precipitate sank in the inner-surface of the reducer.
b. Lubricating oil has emulsified.
c. Lubricant has been polluted by the materials, such as mud, sand and metal particle
etc.

Table 3 Pumping unit lubricating table


Lubrication grease(oil) Volume(L) Period
Lubricating
Item Nos
position Surrounding
Grade Add Change Add Change
temp.°F
Carrier bar As
① 1 Steel cable grease As required
and wire line required
Center 3# lithium based As
② 1 0.3 1 Half year
bearing seat grease required
Cross beam 3# lithium based As
③ 1 0.2 0.8 Half year
bearing seat grease required
Crank pin 3# lithium based As
④ 2 0.2 0.5 Half year
bearing grease required
Down to ISO VG
–30°F 150 Extreme See
As As
⑤ Gear reducer 1 pressure specs Half year
Down to ISO VG required required
lub. oil table
0°F 220

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Note: to use grease to lubricate, add lubricating grease every half-year. Avoid adding oil in winter.

Exchanging lubricating oil should pay attention to:

1) Before changing the lubricating oil of the reducer, oil should be discharged and
completely flushed with oil solvent. After flushed, solvent should be discharged, and then
flushed again with a little of lubricating oil. After the flushing oil discharged, new
lubricating oil should be put in at once.

2) After having changed lubricating oil, don’t run the pumping unit at once, the reducer
should work at least 10 minutes to confirm to cover a oil layer of maintenance in the
surface of the reducer gear.

Filling lubricating should pay attention to:

1) Reducer lubricating oil level should be in upper lever and lower level. Low oil level can
lead to gears and bears bad lubricating. High oil level can lead to reducer oil leak.

2) At the back of reducer, there are two screw holes, which show the upper and lower oil
level.

Note: Crank pin bearing, cross beam bearing and center bearings assemblies are all
have been lubricated at the factory; however it is recommended that all bearing
assemblies be rechecked for proper grease prior to starting unit. Using approved grease;
pump the grease into each bearing assembly until it overflows through the relief fitting
located in the bearing cover plate. Always pump grease in slowly to avoid damage to the
oil seals.

In addition, hanger screw jack, horse head pin, connection rod pin, brake safety
assembly shaft, brake level pin and so on should be added lubricating oil to rust
prevention or make some of them rotate agilely.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

8. SECTION EIGHT. MAINTENANCE

SAFETY STOPS
To prevent accidental injury to nearby persons, install safety devices to
prevent movement of crank arms or walking beam.

The unit may have some problems during its running; you can locate the cause and take
necessary corrective actions according to the table 4.

Table 4 Trouble Shooting


Troubles Cause Troubleshooting
1. Insufficient bearing capacity of
Drain water; compact soil; install pumping unit
ground, or water soaked under the
again.
concrete foundation.
Packing the concrete foundation, install pumping
2.Unbalanced concrete foundation.
unit again if necessary.
Check main base for rigidity, tighten up the
3. Unbalance main base
pressing bar bolts.
4. Main base break Repair or replace the main base.
5.The horse bolt of subsurface fail to
Tighten up the losing bolt
tighten up
Adjust the pumping unit and make the deviation of
the central line of the main base and the well head
6.Misaligned to well head be less than 3mm(0.12in), The diameter deviation
of the suspending point's projection and the
Pumping unit
unbalanced wellhead diameter is less than Ф18mm(Ф0.7in).
vibration Suspending point's load should meet the
7.Polish rod over-loading
requirement of the manual.
8.unsufficient load of the polished Suspending point's load should meet the
rod requirement of the manual.
9.Pumping unit unbalanced Adjust balance
10.Horse head failure Refer to horse head failure section
11.Walking beam failure Refer to walking bean failure section
12.Center bearing seat and center Refer to center bearing seat and center shaft seat
shaft seat failure failure section
13.Samson post failure Refer to Samson post failure section
14.Cross beam failure Refer to cross beam failure section
15.Pitman failure Refer to connection rod failure section
16.Crank pin failure Refer to crank pin failure section
17.Crank failure Refer to crank failure section
18. Reducer failure Refer to reducer failure section

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Continued with
Troubles Cause Troubleshooting
1.The steel cable has lacked grease and
Add lubrication grease
dried
The wire line
2. Parts of the steel cable has been
abnormally works Change wire line
broken
3. The wire line cap has been loosen Change wire line
Steel cable twist
Carrier bar not The steel cable is not properly adjusted. Adjust the steel cable
straight.
Connection of Carrier 1.The size of polished rod clip and
Replace the polished rod clip
bar and polished rod polished rod un-matching
loosed 2. Polished rod clip worn. Change the polished rod clip
1.The wire line failure Refer to wire line failure section
2. There is friction between wire line and
Adjust walking beam or Samson post or base
the said plate of the horse head
3.The pin of the horse head has been
Horse-head Tighten up it
loosen
abnormally works,
4.The pin of horse head has been worn Change it
vibrating and having
5.The weld joint of the horse head has
noise Repair or change horse head
been broken
6.The said plate of the horse head has
Repair or change horse head
been broken
7.The horse head has sloped Adjust walking beam or Samson post or base

1.The bolts of center bearing seat are Adjust the walking beam, and make the deviation
loosen of the suspending point's projection with center
Walking beam was line of well head be less Ф18mm(0.7in), adjust
displaced or deviated the place of the walking beam, tighten up the
breadth wise. 2.The bolts of center shaft seat are bolts of the center bearing seat, tighten up the
loosen bolts of the center shaft seat, tighten up pulling
3.The pulling bolts of center shaft seat bolts of center shaft seat
are loosen
1.The bearing is worn Change the bearing

The center bearing


2.Lack of lubrication grease in the
seat and center shaft Add lubrication grease
bearing of the seat
seat abnormally
works and having 3.The bolts of the bearing cap are
abnormal noise Tighten up the bolts
loosen
4.The gland bolt of the bearing seat
Tighten up it
loosen
Pitman touch the
crank or counter Walking beam is deviant installation Adjust walking beam position
weight

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Continued with
Troubles Cause Troubleshooting
Pitman can’t rotate Pitman pin has been rusted Add lubrication grease
1.The bolts which connect Samson post
Tighten up the bolts
and main base are loosen
The Samson post Use the plumb bob to adjust the deviation of the
vibrates, wave center of the beam and the marking hole of the
seriously or has 2. The Samson post un-compact main base is less 5mm(0.2in), add the gasket
position leaning, under the connection board of the supporting
frame, tighten up the bolt of the Samson post.
3.Base failure Refer to base failure section
1.The bearing is worn Change the bearing
Tail bearing
2.Lack of lubrication grease in the bearing
abnormally works and Add lubrication grease
of the seat
having abnormal noise
3.The bolts of the bearing cap are loosen Tighten up the bolts
1.Ential bolts of the crank (the axle of the
Crank runs reducer and the locking bolts for the crank Tighten up the bolts
hole) are loosen
abnormally, loses its
2.Wedge key has been broken Change it
speed or vibrates or 3.The key-slot of the input shaft of the Use another key-slot of the input shaft reducer
jumps reducer has been broken
4.The key-slot of crank broken Change crank
1. Pumping unit is overloaded. Operate the pumping unit according to manual.
2.Insufficient load Operate the pumping unit according to manual.
3. Stork frequency is more than usual. Operate the pumping unit according to manual.
4. Pumping unit is unbalanced. Adjust the pumping unit to balance.
Crank pin works
5. Connection rod is interfered by crank Adjust the position of the pumping unit or adjust
abnormally.
pin. the assemble position between connection rod
Periodic noise from
and crank pin. The difference distance between
crank pin.
each connection rod inside and crank processed
Crank pin displaced
surface must be less than 3mm(0.12in).
on axial direction.
6. Crank pin and crank pin hole is not Check the cone surface of crank pin and crank
mated tightly. pin jacket. If they are worn, change them.
7. The mated surface between Crank pin Clean the crank pin, the crank pin cone jacket
and crank pin hole is not clear. and the crank pin hole.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

Continued with
Troubles Cause Troubleshooting
8. The nuts of crank pin are loosening. Tighten the nuts, install the nuts cover sheet and
loose-proof steel sheet, tighten loose-proof bolts,
bend loose-proof steel sheet to against the bolts,
tie loose-proof iron line.
9. Left-hand thread and right-hand thread Left-hand thread crank pin should be installed at
crank pins are installed incorrectly. the left side of pumping unit. Right-hand thread
crank pin should be installed at the right side of
pumping unit.
1. Lubrication oil is insufficient. Check lubrication oil level and add more
Gear reducer's lubrication oil
bearings are over hot 2. There is friction on bearing cover or Check and adjust sealing part and tighten the
or noisy. sealing part. belts on bearing cover.
3. Bearing is worn. Change the worn bearing.
1. Pumping unit is unbalanced. Adjust the pumping unit to balance.
2. There is friction on bearing cover or Check and adjust sealing part and tighten the
sealing part. belts on bearing cover.
Abnormal noise in 3. Bearing clearance is too big or too Adjust bearing's clearance.
gear reducer, or small.
reducer shocking. 4.Surface of reducer gear is worn. Change gear or gear shaft.
5. Helical gear key slot is loose. Disassemble and repair.
6. Reducer inside shaft is loosely mated Change reducer.
with gears and displaced.
1. Too much lubrication oil. Discharge some oil and situating oil level to
Reducer leakage
stipulated position.
2. Belts connecting reducer up body and Tighten the belts evenly.
down body are loose.
3. Reducer up body and down body Open reducer cover and clean connecting
connecting surface is not bonded or surface. Paint sealing gum on the connecting
sealed. surface evenly, then close the cover and tighten
Reducer leakage box belts evenly.
4. Oil discharge plug or oil level plug is not Tighten the plugs.
twisted tightly.
5. Bearing cover is not pressed tightly. Tighten bearing cover belts.
6. Bearing sealing ring is worn. Change bearing sealing ring.
7 Oil returning hole is blocked. Ball out the oil return hole.
1. Reducer is over loaded. Operate the reducer according to manual.
Gear surface is worn. 2. Pumping unit is unbalanced. Adjust the pumping unit to balance.
Gear has continuous 3. Lubrication oil is insufficient. Add more lubrication oil to the stipulated level.
spot corrosion or has 4. Lubrication oil is improper type. Change it with proper type oil.
been scratched. 5. Lubrication oil is deteriorated. Discharge all used lubrication oil, clean the
inside of reducer and add in stipulated oil.

Continued with
Troubles Cause Troubleshooting
Reducer gears and Lubrication oil has been contaminated by Clean the inside of reducer and change
bearings are worn abrasive substance. lubrication oil.
rapidly.
1. Lubrication oil has been used for a long Change lubrication oil.
Sticky and insoluble time.
sediment on reducer
gears and bearings 2. Lubrication oil has been contaminated. Change lubrication oil.
surface. 3. Lubrication oil is not the proper type. Change it with proper type oil.
1. Discontinuous running under humid Add corrosion inhibitor into lubrication oil.
circumstance.
Gear and bearing of
2. Water is in reducer box. Discharge the water.
the reducer is rusted
seriously and corroded 3. Lubrication oil is not the proper type. Change it with proper type oil.
extensively.
4 Lubrication oil is deteriorated. Change lubrication oil.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

5. The inside of reducer can’t be Clean and ball out the breather hole.
ventilated well. Breather hole was
plugged.
Reducer heated and 1. The quantity of lubrication oil is much Add or reduce lubrication oil to stipulated level.
temperature of oil in oil more or less than stipulated.
sump is more than 60 2. Lubrication oil is not the proper type, or Check and change the lubrication oil.
0
C. lubrication oil is deteriorated.
1. The viscosity of lubrication oil is too Reduce the viscosity of lubrication oil or change
Difficult to start the
high lubrication oil.
reducer in winter.
2. Lubrication oil is ineffective. Changer lubrication oil.
1. Brake clearance is not adjusted Adjust brake clearance.
properly.
Pumping unit can't be
braked or brake 2. Brake block is worn. Change brake block.
automatically.
3. There is oil filth between the brake Get rid of the oil filth.
block and brake drum.
1. The fixed bolts of the motor are loose. Fix the bolts.
Inhomogeneous noise 2. Motor bearing is short of lubrication oil. Inject lubrication oil.
of the motor
3. Motor bearing was worn. Change motor.
1. Belts are lengthened evenly. Adjust motor center.
Belts are loose or 2. The length of belts is different. Use the belts with the same length.
sliding.
3. The fixed bolts of the motor are loose. Fix the bolts.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

9. SECTION NINE. QUALITY WARRANTY

9.1 CONTENT AND VALIDITY OF WARRANTY

If pumping unit accident occurs in the period of guarantee, we provide the following to
quality:

We made a period of guarantee that is from pumping unit leave factory 60 months, and
in the period of guarantee we warrant that the goods under normal operating condition
will be free from repairing.

We are responsible for only to pumping unit and don’t indemnify to other and any bodily
injury.

9.2 CONTENT OUT OF WARRANTY

The following situation is out of warranty:

1) Modification without our written agreement.


2) The accident or damage caused by the foundation sinking or improperly cast
foundation.
3) Main base fissures caused by the unsteady foundation.
4) The failure, accident or damage caused by breach of the required installing,
operating or maintaining in this manual.
5) The failure, accident or damage caused by breach of operating rule.
6) Lubricant is not the required type.
7) The pumping unit is operated in excess of overloaded condition or under min
suspended load condition.
8) The pumping unit is operated under seriously unbalance conditions.
9) Accident or damage occurred out of our responsibility.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

9.3 CONSUMABLE ACCESSORIES LIST

In the period of pumping unit leaving factory 12 months, if the following parts or(and)
accessories damages or(and) wear abrasion occur, they will be free and supplied by
manufacturer:

1) Zerk (for feed lubrication system grease).


2) Industrial Felt (δ=12 or so, for seal).
3) Asbestos plate (δ=1,1.5,2, for seal).
4) Oil Seal (located in center, tail, and crankshaft bearings).
5) Split Pin (put in brake system etc).
6) Ring –seal (for gear reducer).
7) Other Consumable seal part(s).
8) V—belts (for reducer sheave match mover sheave)etc.

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Conventional Beam Pumping Unit Operation and Maintenance Manual

10. SECTION TEN. APPENDIX

TECHNICAL SPECIFICATIONS

In this section, Technical specifications and configurations of pumping units are shown in
attached table. It provides a reference for users someway.

STROKE FACTORS & TORQUE FACTORS

When verifying or(and) adjusting unit balance, stroke & torque factors are commonly
referred. Stroke factors & torque factors are shown in this section .

RECOMMENDED PRACTICE FOR INSTALLING PUMPING UNIT

For the convenience of installing pumping units, manufacturer have given some guide for
users, these are sketches of installation of main base and concrete foundations.

Recommended installation plans, recommended concrete foundation styles see attached


figs.

For wide-skid, recommended installation plans and concrete foundation styles haven’t
been presented in this manual. If users desire, manufacturer would send similar
information for them in some way availably and timely.

If you have any problems or advise in the unit’s erection, operation or maintenance,
you can contact the manufacturer or the agent.

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